Note: Descriptions are shown in the official language in which they were submitted.
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Process for the preparation of resols
The invention relates to the preparation of phenolic
resins prepared with the aid of metal salts which
catalyze the formation of resols and whose cations. can
easily be precipitated as low-solubility salts in
industrial processes_
Resole bf this type are preferred for various areas of
l0 application owing to their better moisture resistance.
Examples of basic salts of this type are basic alkaline
earth metal salts, in particular calcium hydroxide.
These salts have the advantage over the alkali metal
hyd=oxides usually employed that the resins prepared in
this Tray have a very low content of free phenol and
that the products produced from these resins have
better moisture resistance. After the condensation, the
salts can be precipitated from the aqueous solution by
z0 addition of dilute sulphuric acid, carbon dioxide,
ammonium sulphate, ammonium phosphates or ammonium
carbonates and separated off. 'this gives resins which
are virtually ash-free.
It is a disadvantage of these resins that the insoluble
precipitates formed in their preparation must be
filtered off in a complex process, since otherwise
blockage of the nozzles can occur during processing of
the resins by spraying and can thus result in problems
during processing.
Filtration of the resins is firstly complex and
secondly associated with considerable loss of resins.
In addition, disposal of filter cakes containing
phenolic resins to landfill is expensive and represents
an environmental problem,
- A solution to these problems are phenolic resins in
which calcium ions are bound to the resins in the form
of complexes with the aid of ammonia or amines, as
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disclosed in EP-A 0 19A 130 and EP-A 0 190 466.
However, these complexes have only moderate stability.
Within a few hours, precipitates form in the
corresponding resin solution, and consequently these
resins can only be employed if they are processed
further immediately after the complexing_ This is
generally not the case, since the resin manufacturer is
not the processor.
In addition, it has been found that calcium carbonate
present in technical-grade calcium hydroxide likewise
interferes with the processing of these resins and
promotes further precipitations.
It is therefore an object of the invention to provide
resole which are simple to prepare and which give
products having good moisture resistance. It is a
further object of the invention that these resols have
no interfering precipitations on neutralization with
ZO the usual neutralizing agents used, such as sulphuric
acid, carbon dioxide, ammonium sulphate, ammonium
phosphates or ammonium carbonate, and in which
impurities of industrial products, such as, for
example, calcium carbonate, have no interfering
effects.
The object is achieved by a process according to Claims
1 to 6. The resins prepared using the process accozding
to the invention are used, in particular, as binders
for the production of acoustic and thermal insulating
materials, wood materials, foams and laminates
according to Claims 7 to l0.
In phenolic resins condensed with the aid of alkaline
earth metal ions, it has been attempted to keep the
alkaline earth metal ions in solution with the aid of
complexing agents in such a way that a good shelf life
is achieved. This was not successful_ As a
corresponding comparative example shows, addition of
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conventional complexing agents to a resin solution
prepared with the aid of alkaline earth metal ions did
not result in the.desired effect of complexi.ng of the
metal ions.
EP-A 890 613 teaches to mix a urea-modified phenolic
resin which has been condensed with the aid of alkaline
earth metal hydroxide with a chelating agent and a
polymeric anionic dispersant after the condensation
reaction in a single working step. on repeating this
teaching (Example ~), however, it was found that a
precipitate is nevertheless formed and must be filtered
off. In addition, the products obtained have a dark
colour, which restricts their use in all cases where a
pale hue is desired, such as, for example, on use in
the mineral wool industry.
Surprisingly, however, it has been found that mixing of
the resin solution of a phenolic resin prepared with
the aid of alkaline earth metal hydroxide with a
commercially available complexing agent allows
complexing of the metal ions to be achieved if the
resin solution has already been intensively mixed with
a dispersant. The resin here is clearly in dispersed
form_ The resin solution formed in this way is stable.
No precipitate forms _ Even on contact with C02 or even
on passing CO~ into corresponding solutions, no
alkaline earth metal carbonate precipitates_ On the
contrary, alkaline earth metal carbonate particles
present in the resin solution dissolved within a short
time.
It is furthermore surprising that the metal ions in the
resins treated in this way are immobilized in such a
way that they are apparently no longer available for
later reactions with water. The products produced using
the resins prepared in accordance with the invention
are distinguished by very good moisture resistance.
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The condensation reaction of phenolic compounds is
carried out in the manner known per se for the
preparation of resols by heating the reactants in
aqueous solution until the desired degree of
condensation has been achieved. The condensation
partners employed can be any phenolic compounds and
aldehydes known for the preparation of phenolic resins.
Phenolic compounds are, in particular, phenol, but also
aliphatically or aromatically substituted phenols, and
polyhydric phenols. Examples of these are cresols,
xylenols, tert-octylphenol, naphthols, p-phenylphenol,
bisphenols and resorcinols, but also natural products,
such as, for example, cardenol, cardol and tannin_ The
phenolic compounds can be employed as individual
compounds or in any desired mixtures with one another.
A'l.dehydes which can be employed are all compounds of
the general formula R-CHO_ Examples are formaldehyde,
acetaldehyde, propionaldehyde, n-butyraldehyde and
isobutyraldehyde, glyoxal_ and furfural. The preferred
aldehyde is formaldehyde, which is employed as such or
in the form of a formaldehyde-eliminating substance,
such as, for example, paraformaldehyde or trioxane. The
preferred form of addition is an aqueous solution
having a formaldehyde content of greater than 30%
(formalin). The molar ratio between phenolic compound
and aldehyde can be selected as desired in the range
from 1 . 1.2 to 1 _ 4 ,
Catalysts which can be employed in the process
according to the invenr,ion are metal salts which
catalyze the formation of resols and whose cations can
easily be precipitated as low-solubility salts in
industrial processes. Examples are magnesium oxide,
magnesium hydroxide, the hydroxides of the alkaline
earth metals calcium, strontium and barium, and salts
thereof with weak acids, but also weakly basic salts of
the transition metals, such as, for example, ainc
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acetate and manganese octanoate_ The preferred catalyst
is calcium hydroxide.
The amount of catalyst employed is in the range from 1
to 15% by weight, preferably in the range from z to 6%
by weight, based on the amount of phenolic compound
employed,
The dispersants employed can be any commercially
l0 available substances which are marketed as dispersants,
emulsifiers, wetting agents or anti~deposition agents
for aqueous systems. Examples are ammonium acrylates,
phosphonium salts, polyalkoxy compounds, such as, for
example, alkylarylpolyethylene glycols, salts of fatty
acids, in particular of alkylarylcarboxylic acids,
alkylbenzenesulphonates, alkylnaphthalenesulphonates or
sulphonates of products of the condensation of
naphthalene or alkylnaphthalene with formaldehyde,
alkyl sulphates or betaines. Preference is given to
2o ammonium polyacrylates or alkylnaphthalenesulphonates.
In an amount of from 0.05 to 5%, based on the phenolic
compound employed, they are added to the reaction
mixture comprising phenolic compounds, aldehyde and
catalyst and mixed intensively_ They can be added
either before, during or after the condensation
reaction. In the latter case, the dispersant can be
added to the reaction mixture before the neutralization
or thereafter_ The crucial factor in all cases is that
the resin is in some type of dispersed form, with the
aid of the added dispersant, before addition of the
chelating agent. This generally requires intensive
mixing of the reaction mixture with the dispersant for
several minutes, at least to minutes in customary
stirred reactors used in the preparation of the resins,
before the complexing agent is added.
Complexing agents which can be employed are all water-
soluble compounds known per se which form chelates with
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metal ions. Examples are ketocarboxylic acids,
dimethylglyoxime, aminopolycarboxylic acids,
diethylenetriaminepentaacetic acid, but in particular
nitrilotriacetic acid (NTA) and ethylenediaminetetra
acetic acid (EDTA).
They are preferably employed in an amount which is
stoich.iometrically sufficient to complex the metal ions
of the catalysts employed, an excess of up to 10%
preferably being selected in order to achieve a
satisfactory complexing rate. A further excess does no
harm, but is inappropriate for economic reasons.
However, addition of a slightly sub-stoichiometric
amount of complexing agent also results in transparent
resin solutions.
The complexing agent is added after the condensation
reaction is complete and after the freshly prepared
resin solution has been mixed with the dispersant. The
complexing agent can likewise be added to the resin
solution either before or after neutralization of the
reaction mixture.
If the complexing agent is added before the
neutralization, precipitations do not form even on
neutralization with acids which per se lead to low-
solubility precipitacions of the corresponding metal
salts.
If the complexing agent is added after neutralization
with an acid which has already led to precipitation,
this precipitation dissolves within a short time, and
an infinitely water-dilutable resin solution forms.
Likewise, low-solubility salts present in the resin
solution, which are in the form of impurities in the
technical-grade qualities employed of the metal salve
used as catalyst, dissolve after a short time.
These resin solutions have a shelf life of several
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weeke without any precipitations of insoluble metal
salts appearing. They can thus be processed in common
processes, accordingly also in spray processes, even
after' extended storage and transport times, ~rithout the
fear of precipitating salts resulting in blockage of
the nozzles.
The resin solutions are transparent and exhibit
excellent impregnation behaviour. They can be cured in
the conventional manner for standard resols, i.e. they
are self-curing on exposure to heat, but can also be
employed in combination with curing agents known per
se, in particular with acids. They can likewise, as is
also known of standard resols, be combined with other,
preferably water-soluble, thermosetting and thermo-
plastic resins. Owing to these properties, they are
particularly suitable for the production of laminates
and foams.
The cured resins exhibit excellent mechanical strengths
and very good moisture resistance. They are therefore
preferably suitable for the production of acoustic and
thermal insulating materials and wood materials.
Z5 Examples
The amounts given in the Examples are in each case
parts by weight (pbw). The dispersant employed in
Examples 1 and 5 is an ammonium polyacrylate
(Nopcosperse~). The dispersant employed in Example 2 is
diieobutylnaphthalenesulphonate (Nekalm HX).
Example 1
100 pbw of phenol are mixed in a reactor with SO pbw of
water and 4 pbw of slaked lime and heated to
237.5 pb~r of 45% formalin solution are then added, and
the reaction mixture is condensed at 70°C to a water
dilutability of 1 . 10. 62.7 pbw of urea are then
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added, follo~.red by 0.5 pbv of diapersant.
After the reaction mixture has been stirred for 2 hours
and cooled, 1 pbw of complexing agent (Na salt of
ethylenediaminetetraacetic acid) is added, and the
mixture is stirred for a further 15 minutes.
The reaction mixture ie then neutralized to pH ~ using
dilute sulphuric acid. The reaction solution remains
clear. No precipitations are observed. Even after a
storage time of 4 weeks at room temperature, no
precipitations are observed.
Example ~
100 pbw of phenol are mixed in a reactor with 50 pbw of
water and 5 pbw of slaked lime and heated to ~o°C.
237 pbw of 45% formalin solution are then added, and
the reaction mixture is condensed at 7o°C to a water
dilutability of 1 . l0.
After the mixture has been cooled ~0 23°C, Z pbw of a
50% strength aqueous solution of Nekal° HX are added as
dispersant, and the mixture is stirred vigorously for
30 minutes. 10 pbw of a 10% strength agueous solution
of the Na salt of nitrilotriacetic acid are then added,
and the mixture is homogenized.
The reaction mixture is then neutralized to pH 7 using
dilute 6ulphuric acid, The reaction solution remains
clear. Even after 4 weeks (storage at room tempera-
ture), no precipitations are observed_
8xample 3 (comparative example)
Example 1 is repeated, the only change being that no
dispersant is added.
On neutralization of the reaction mixture using
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eulphuric acid, calcium sulphate deposits in the form
of a microcrystalline precipitate.
Example 4 (comparative example)
Analogously to Example 1,100 pbw of phenol and 250 pbw
of 45% formalin are condensed with one another at 70°
in a reactor. The catalyst employed is 6.7 pbw of 50%
strength sodium hydroxide solution. After the
condensation, 15 pbw of urea are added to the reaction
mixture, and the mixture is subsequently neutralized
using dilute sulphuric acid.
Example 5 (comparative example)
Analogously to Example 4, 100 pbw of phenol and 210 pbw
of 45% formali.n are condensed with one another_ The
catalyst employed is 7.5 pbw of triethylamine_ After
the condensation, 75.8 pbw of urea are added to the
z0 reaction mixtu='e, and the mixture is subsequently
neutralized using dilute sulphuric acid.
Test results for the resins from Examples 1 - 5
The resins are analyzed in a conventional manner. zn
addition, the flexural strength of corresponding test
bars is determined. In order to produce the test bars,
each of the resin solutions is adjusted to a solids
content of 40%. to pbw portions of these solutions are
each mixed with 100 pbw of quartz sand, and the mixture
is introduced into moulds (170 x 22 x 22 mm) and cu=ed
in these moulds for 2 hours at 180°C in the oven. The
flexural strength is tested:
a. in the dry state
b. in the wet state after storage for 6 hours in
water at 100°C and cooling for 1 hour in
running water at a maximum of 20°C.
The results obtained are shown in Tables 1 and 2 below:
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Table 1 (analyses)
Example Example Example Example Example
1 2 3 4 5
Refractive 1_4550 1.4742 1.4650 1.4540
isidex
Solids 45.0 45_2 43.0 49.0 47.0
content [%]
Free phenol < 0.3 0.42 < 0_3 < 0.5 < 0.7
(%)
Free form- < 0_5 8.2 < 0.5 7.0 < 0.5
aldehyde
[%]
pH 7 7 7 8.A 8_6
Watez m m m m m
solubility
a time at 7 4 13 5 14
13 0 C [min)
Table 2 (flexural strength [MPaJ )
dry wet
Example 1 8.1 7.9
Example 2 8.7 8.1
Example 3 7_9 6.5
Example 4 7_5 4.1
Example 5 7.9 5.1
5
Example 6
Analogously to Example 1, 100 pbw of phenol are
condensed with 14z pbw of 45% formalin. The catalyst
to used ie 5 pbw of barium hydroxide. After the
condensation, 0.5 pbw of dispersant is added, and the
reaction mixture is stirred for 2 hours. 182 pbw of the
Na salt of ethylenediaminetetraacetic acid are then
added, and the mixture is stirred for a further 30
minutes. 0.5 pbw of alkylsulphonic acid, 5 pbw of
_ pentane and 5 pbw of p-toluenesulphonic acid are
subsequently added, and the mixture is foamed at 60°C.
The compressive strength of the foam is determined by
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the Chatillon method. The result is given in Table 3.
Example 7 (comparative example)
A resin is prepared analogously to Example 6, the only
change being that no dispersant is added_ on addition
to the mixture to be foamed, an insoluble barium salt
of p-toluenesulphonic acid precipitates out and slowly
deposits in the reaction mixture. The resultant foam is
l0 thus inhomogeneous_
Table 3 (compressive strength of the foams [Pa])
Example 5 70
Example 6 56
Example 8 (comparative example)
100 pbw of phenol are mixed with 27_3 pbw of water and
B.8 pbw of slaked lime in a reactor and heated to 70°C_
227 pbw of 45% formality solution are then added, and
the reaction mixture is condensed at 7o°C to a water
dilutability of l:~.o_ After the mixture has been cooled
to 60°C, 32 pbw of water and 54.7 pbw of urea are
added. The mixture is then immediately cooled to 45 °C
alld held at this temperature for 30 minutes.
After the mixture has been cooled to 23°C, 0_5% APHT
(1% Hayhibit~ AM 50%) and 0.15% sodium ligninsulphonate
(Vanisperae~ CH) are added shortly one after the other
with vigorous stirring.
Analysis of the resultant resin:
nD value : 1 _ 4635
pH: 8.8
Density at ZO°C: 1.195 g/cm'
Free formality: 0_5%
Free phenol: 0.33%
Dry resin: 46.1%
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Water solubility: infinite, but formation of
a precipitate which set-
tles
Colour. black-brown.
